Controlled environment fastener head painting device and method

Abstract

A painting apparatus for applying a coating material to a member surface of a member comprises a housing, at least one slide rail, a rack assembly, a cross beam and a spraying device. The slide rail may be mountable within the housing and may have a plurality of rack positions. The rack assembly is mountable within the housing at one of the rack positions. The rack assembly is configured to support the member such that the member surface is exposed. The cross beam may be coupled to the slide rail. The cross beam is movable along the slide rail and is positionable at the rack positions. The spraying device is mountable on the cross beam and is configured to move along the cross beam while spraying the coating material onto the member surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001](Not Applicable)STATEMENT RE: FEDERALLY SPONSORED RESEARCH / DEVELOPMENT[0002](Not Applicable)FIELD[0003]The present disclosure relates generally to coating systems and, more particularly, to controlled-environment painting apparatuses for applying coatings to a plurality of items such as mechanical fasteners.BACKGROUND[0004]Manufacturers are continuously implementing new production techniques and build philosophies in efforts to reduce production cycle time and cost. Particularly for manufacturers of large-scale assemblies such as commercial aircraft, minor improvements to the production process can lead to appreciable reductions in production time and cost. One approach to reducing production cycle time and cost is to reduce the amount of labor required at final assembly. In this approach, instead of receiving a multitude of individual components and partially-completed subassemblies from a variety of different subcontractors for final as...

AI Technical Summary

Benefits of technology

[0012]The painting apparatus may be provided in a relatively small size to facilitate transporting thereof to different locations such as different locations of a manufacturing or assembly facility. In addition, by providing the painting apparatus in a relatively small size, the temperature and humidity level of an interior environment of the painting apparatus may be easily controlled and maintained such as by using a pressurized air source. Even further, the relatively small size may simplify construction and reduce the cost of the painting apparatus as compared to relatively large, stationary paint booths and curing ovens which may be more costly to construct, operate and maintain and which may permanently occupy a relatively large area.

[0013]The painting apparatus may used to apply a variety of different coating materials to the surfaces of the members at a controlled sweep rate and at a controlled standoff distance from the member surfaces of the members. In addition, the painting apparatus allows for the application of coating materials in an automated manner in order to improve the accuracy and consistency of film thickness, coating adhesion and finish appearance as compared to prior art methods that rely on manual application by skilled operators.

[0017]The movement of the cross beam along the one or more slide rails may be driven by any suitable power source including, but not limited to, pneumatic, electrical, hydraulic, and / or mechanical power or various combinations thereof such as electro-mechanical power, hydro-mechanical power or by power provided by an internal combustion engine or the cross beam may be manually-driven. In an embodiment, pneumatic power may be used in combination with one or more air motors that may be mounted at any suitable location on the painting apparatus. For example, at least one air motor may be mounted on at least one slide rail such as at one of opposing ends of the slide rail. Likewise, movement of the spraying device along the cross beam may be driven by any suitable power source such as any of the power sources indicated above with regard to driving the cross beam along the slide rails. In an embodiment for driving the spraying device along the cross beam, pneumatic power may be used in combination with one or more air motors mounted at any suitable location such as at one of opposing ends of the cross beam. Advantageously, the use of pneumatic power to drive the movement of the cross beam and the spraying device may avoid hazards normally associated with flammable gases or vapors in the presence of an electrical source of ignition such as electrically-powered motors.

[0019]The housing may be enclosable using one or more removable or pivotable doors and / or lid in order to form an environmentally-controllable chamber. The air source may maintain the temperature and / or relative humidity level of the chamber during application of the coating material and during curing of the coating material which may be different that the temperature and humidity level required during application of the coating material.

[0021]Once the panels are loaded onto the rack assemblies in the housing, the cross beam may be successively moved to each rack position. At each rack position, the spraying device may move along the cross beam spraying coating material onto the member surfaces of one or more members such as fasteners that may be loaded in the rack assembly at that rack position. After the coating material is sprayed onto the member surfaces of the members, an ejection or lifting mechanism may be employed to lift the members such that the member surfaces may be separated from the upper surface of the rack assembly. For example, for configurations wherein the member is a fastener having a head and a shaft, the lifting mechanism may push upwardly on the shaft to lift the fastener head away from the upper surface of the rack assembly to prevent paint bridging between the heads and the upper surface of the rack assembly. The lifting mechanism may maintain the member surfaces (e.g., heads) in spaced relation to the upper surface during curing of the paint. Following curing of the coating material on the member surfaces, the panels may be removed from the housing after which the members may be removed from the panels.

Problems solved by technology

Considering the large quantity of subassemblies that make up a commercial aircraft and the overall size of such aircraft, the quantity of fasteners that must be provided in a pre-painted condition may be relatively large.

Difficulties in meeting film thickness requirements can occur as a result of inconsistencies during manual application of paint.

Furthermore, inappropriate temperature and humidity levels during application of the paint and during curing of the paint can result in inconsistencies in adhesion and appearance (e.g., runs, wrinkles) of the painted fastener heads.

As a result of such stringent requirements, the number of subcontractors that are qualified to provide painting services may be limited.

The limited number of qualified subcontractors may impact the ability to provide the large quantity of pre-painted fasteners on schedule.

Difficulties in meeting schedule may be exacerbated by subcontractors that are qualified but are located remotely from the manufacturer such as in out-of-state locations.

Furthermore, the remote location of such qualified subcontractors may limit the ability to procure pre-painted fasteners on an emergent need basis at final assembly.

Such emergent need may occur as a result of part shortages on the production line.

Although the erection by the manufacturer of an on-site painting facility and curing oven may eliminate problems associated with the limited availability of qualified subcontractors, the construction of such a facility would defeat the goal of shifting a larger share of the production process to the subcontractors.

Furthermore, the construction, operation and maintenance of an on-site painting facility and a curing oven having the requisite temperature and humidity control capabilities may be prohibitively expensive.

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